Layered Tube for Improved Kink Resistance

ABSTRACT

A catheter shaft is produced by forming a first polymeric layer onto a flexible inner core while maintaining the inner core in a solid state, and solidifying the first polymeric layer, wherein the solidified first polymeric layer fails to bond with the inner core and is slidable thereon upon flexion of the shaft. A second polymeric layer may be formed over the first polymeric layer, and is slidable thereon when the shaft bends.

CROSS-REFERENCE TO CO-PENDING APPLICATION

The present application is a Divisional Application under 35 U.S.C. § 121 of U.S. patent application Ser. No. 15/386,461, filed Dec. 21, 2016. The entire content of this application is incorporated by reference herein in its entirety.

COPYRIGHT NOTICE

A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.

BACKGROUND OF THE INVENTION 1. Field of the Invention

This invention relates to instruments for performing medical examinations of the interior of cavities or tubes of the body. More particularly, this invention relates to a medical catheter constructed by a process for applying fluent materials to a surface or part of a surface.

2. Description of the Related Art

It is common to map and ablate endocardial tissue in subjects having electrical conduction abnormalities. The procedures are performed with an elongate catheter having a lumen extending longitudinally through it. One technique, described in U.S. Pat. No. 5,993,462, involves inserting a core wire into a catheter via the lumen. The core wire includes a pre-shaped region. Such catheters includes a proximal section that is sufficiently rigid to straighten the core wire when the core wire is disposed within the proximal section. A distal section of the catheter is significantly more flexible than the proximal section.

Deflectable catheters are widely used for a variety of applications. In the area of electrophysiology. However, due to their inherent flexibility and limited kink resistance, catheters can be difficult to control as precisely as would be desired. Conventional approaches to increasing kink resistance include: increasing wall thickness, reinforcing the wall with a coil, replacing a large open lumen with a multi-lumen arrangement, or changing the material so that it can stretch and bend more easily.

SUMMARY OF THE INVENTION

According to disclosed embodiments of the invention, a catheter shaft is constructed using multiple film-cast, extruded or coextruded layers of materials that do not chemically bond together. The layers are in extremely good mechanical contact, but when the construction is bent, they are able to slip with respect to each other, which makes the tube more resistant to kinking.

There is provided according to embodiments of the invention a method of making a catheter shaft, which is carried out by forming a first polymeric layer onto a flexible inner core while maintaining the inner core in a solid state, and solidifying the first polymeric layer, wherein the solidified first polymeric layer fails to bond with the inner core and is slidable thereon upon flexion of the inner core.

According to one aspect of the invention wherein forming the first polymeric layer is extruded.

According to yet another aspect of the method, the first polymeric layer is film cast.

A further aspect of the method is carried out by forming a second polymeric layer onto the solidified polymeric first layer, and solidifying the second polymeric layer, wherein the solidified second polymeric layer fails to bond with the solidified first polymeric layer and is slidable thereon upon flexion of the inner core.

According to an additional aspect of the method, the second polymeric layer is extruded.

According to still another aspect of the method, the second polymeric is film cast.

According to yet another aspect of the method, a kinetic coefficient of friction between the solidified first polymeric layer and the solidified second polymeric layer does not exceed 0.5.

According to still another aspect of the method the solidified first polymeric layer and the solidified second polymeric layer are composed of identical materials.

According to an additional aspect of the method, the solidified first polymeric layer and the solidified second polymeric layer are composed of polyimide.

According to a further aspect of the method the solidified first polymeric layer and the solidified second polymeric layer are composed of different materials.

According to another aspect of the method, one of the solidified first polymeric layer and the solidified second polymeric layer is ultra-high-molecular-weight polyethylene and another of the solidified first polymeric layer and the solidified second polymeric layer is polyether block amide.

According to one aspect of the method, the inner core includes a metallic braid.

There is further provided according to embodiments of the invention a catheter shaft having a flexible inner core, a first polymeric layer formed onto the flexible inner core, and a second polymeric layer onto the first polymeric layer, wherein upon flexion of the flexible inner core the first polymeric layer is slidable on the flexible inner core and on the second polymeric layer.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

For a better understanding of the present invention, reference is made to the detailed description of the invention, by way of example, which is to be read in conjunction with the following drawings, wherein like elements are given like reference numerals, and wherein:

FIG. 1 is a schematic diagram of a medical catheter according to an embodiment of the invention;

FIG. 2 is a cross sectional view of the shaft of the catheter shown in FIG. 1 in accordance with an embodiment of the invention; and

FIG. 3 is a group of two schematic longitudinal sections of portions of the shaft of the catheter shown in FIG. 1 in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

In the following description, numerous specific details are set forth in order to provide a thorough understanding of the various principles of the present invention. It will be apparent to one skilled in the art, however, that not all these details are necessarily needed for practicing the present invention. In this instance, well-known circuits, control logic, and the details of computer program instructions for conventional algorithms and processes have not been shown in detail in order not to obscure the general concepts unnecessarily.

Documents incorporated by reference herein are to be considered an integral part of the application except that, to the extent that any terms are defined in these incorporated documents in a manner that conflicts with definitions made explicitly or implicitly in the present specification, only the definitions in the present specification should be considered.

Turning now to the drawings, reference is initially made to FIG. 1, which is a schematic diagram of a medical catheter 10 according to an embodiment of the invention. The catheter 10 comprises an elongated shaft 12 having a relatively stiff proximal section 14, relatively flexible distal section 16 with respect to the proximal section 14 and an intermediate section 18. One or more electrodes or other devices are mounted on the distal section 16 for performing mapping, ablation or another desired function, and a control handle 20 is located at the proximal section 14 of the shaft 12. An infusion tube 22 is provided to introduce fluid through a lumen (not shown) of the shaft 12. A luer hub 24 is mounted on the proximal end of the infusion tube 22 to facilitate introduction of the fluid into the catheter 10.

Reference is now made to FIG. 2, which is a cross sectional view of the shaft 12 (FIG. 1) in accordance with an embodiment of the invention. The shaft is constructed by extrusion or coextrusion of thermoplastic materials, as described in the detailed description below. In the depicted embodiment, the shaft 12 includes lumens 26, 28, 30, 32 surrounded by a relatively soft inner extrusion 34, which is drawn through a metallic braid 36. While 4 lumens are shown, a catheter may comprise more or fewer lumens, depending on the application intended.

The inner extrusion 34 and braid 36 are surrounded by a series of layers. Respective outer, middle, and inner layers 38, 40, 42 are shown in the example of FIG. 2; however, the shaft 12 may be constructed with more or fewer layers. The layers may be applied in successive extrusion operations using conventional screw extruders, preferably having barrel cooling systems to obtain good mixing efficiency and melt uniformity, and to avoid surge effects. Dealing with these issues is well known in the extrusion art, and is not dealt with further herein. Alternatively, the layers may be coextruded with the inner extrusion 34.

It is important that the layers 38, 40, 42 and the inner extrusion 34 do not bond to one another, although they are in close physical proximity; indeed in “contact with one another. This requirement enables the layers 38, 40, 42 and the inner extrusion 34 to slide upon one another when the shaft flexes. The layers 38, 40, 42 may be constructed of the same material, e.g., polyimide or a thermoplastic such as polyethylene terephthalate (PET), Pebax®, Polyurethane,” or Nylon™. If a thermoplastic is used, layers can be prevented from bonding to one another by keeping each successive inner layer below the melt point of a currently extruding outer layer. When identical materials are used bonding can be avoided if the inner layer is cold and the outer extrusion is put on with at a temperature that is barely high enough for the material to flow. In that case as soon as the outer extrusion touches the inner layer it cools immediately and does not melt into the inner core and form a bond. When film casting is used with polyimide, if the inner layer is solidified it does not make a bond with the outer layer.

Alternatively, the shaft 12 may be built up by alternating layers of different materials that do not bond to each other, for example, ultra-high-molecular-weight polyethylene (UHMWPE) and a polyether block amide, such as Pebax.

Regardless of the materials chosen, it is desirable that there be a low kinetic coefficient of friction between adjacent layers 38, 40, 42 and also between the layer 38 and the inner extrusion 34. A coefficient of friction of 0.5 is satisfactory.

Reference is now made to FIG. 3, which is are schematic longitudinal sections of portions of the shaft 12 in accordance with an embodiment of the invention. In the upper portion of the figure, the shaft 12 is extended. On one side of the shaft 12 marker 44 in the outer layer 38, marker 46 in middle layer 40 and marker 48 in inner layer 42 are aligned with one another and with reference marker 50 in the inner extrusion 34. On the opposite side of the shaft 12, marker 52 in the outer layer 38, marker 54 in the middle layer 40 and marker 56 in the inner layer 42 are also aligned with reference marker 50.

In the lower portion of the figure the shaft 12 is in a state of flexion at an angle of nearly 90 degrees about a pivot point 58. The markers 44, 46, 48, and markers 52, 54, 56 are no longer in alignment with one another nor with the reference marker 50, because the layers 38, 40, 42 have slid over one another and in the case of inner layer 42, over the inner extrusion 34. At the right side of the shaft 12 the markers 44, 46, 48 are now axially displaced relative to the marker 50, generally toward the pivot point 58 in a direction indicated by arrow 60. The marker 44 in the outer layer 38 has the largest displacement from the reference marker 50, with successively smaller displacements of the markers 46, 48. On the opposite side of the shaft 12, the markers 52, 54, 56 are also displaced relative to the marker 50, but in an opposite direction, generally away from the pivot point 58 as indicated by arrow 62. Marker 52 in the outer layer 38 has the largest displacement from the reference marker 50, with successively smaller displacements of the markers 54, 56.

Of the three layers 38, 40, 42, the layer 38 is under the most compression. The movement of the layers with respect to each other has prevented the shaft 12 from kinking tightly despite the flexion.

Alternate Embodiment

Continuing to refer to FIG. 2 and FIG. 3, in this embodiment the layers 38, 40, 42 are formed on the inner extrusion 34, which is now used as a mandrel by a process of polymer solution casting or film casting, which is known in the art. The same materials used in the first embodiment are suitable, as they possess desired characteristics of lubricity and durometer. Moreover, the layers can be prevented from bonding to one another by film casting an outer layer onto a solidified inner layer.

It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather, the scope of the present invention includes both combinations and sub-combinations of the various features described hereinabove, as well as variations and modifications thereof that are not in the prior art, which would occur to persons skilled in the art upon reading the foregoing description. 

1. A method of making a catheter shaft, comprising the steps of: forming a first polymeric layer onto a flexible inner core while maintaining the inner core in a solid state; and solidifying the first polymeric layer, in which the solidified first polymeric layer fails to bond with the inner core and is slidable thereon upon flexion of the inner core.
 2. The method according to claim 1, in which forming a first polymeric layer is performed by extruding.
 3. The method according to claim 1, in which forming a first polymeric layer is performed by film casting.
 4. The method according to claim 1, further comprising the steps of: forming a second polymeric layer onto the solidified polymeric first layer; and solidifying the second polymeric layer, in which the solidified second polymeric layer fails to bond with the solidified first polymeric layer and is slidable thereon upon flexion of the inner core.
 5. The method according to claim 4, in which forming a second polymeric layer is performed by extruding.
 6. The method according to claim 4, in which forming a second polymeric layer is performed by film casting.
 7. The method according to claim 4, in which a kinetic coefficient of friction between the solidified first polymeric layer and the solidified second polymeric layer does not exceed 0.5.
 8. The method according to claim 4, in which the solidified first polymeric layer and the solidified second polymeric layer are composed of identical materials.
 9. The method according to claim 8, in which the solidified first polymeric layer and the solidified second polymeric layer are composed of polyimide.
 10. The method according to claim 4 in which the solidified first polymeric layer and the solidified second polymeric layer are composed of different materials.
 11. The method according to claim 10, in which one of the solidified first polymeric layer and the solidified second polymeric layer is ultra-high-molecular-weight polyethylene and another of the solidified first polymeric layer and the solidified second polymeric layer is polyether block amide.
 12. The method according to claim 1, in which the inner core comprises a metallic braid. 